Caravan Floor Delamination

Modern caravan floors and walls are made of sandwich construction. The floors are constituted of upper and lower sheets of thin plywood bonded to a styrofoam core, while the walls comprise the outer aluminium and the inside wallboard bonded to a polystyrene core. If the bond breaks down, delamination takes place. This is more likely to happen to the floor, which then feels spongy. The obvious sign of wall delamination is the aluminium panel bulging outwards. Both forms of delamination can be effectively cured using a specially-formulated epoxy resin.

This sort of repair should not be attempted by anyone, other than a qualified, experienced caravan repairer. The resin, if used incorrectly, can cause irreversible damage to your caravan. It is for this reason, we do not retail the resin kits.

To repair a delaminated floor:

1. Remove carpet.
2. Drill holes in a matrix pattern to the affected area.
3. Tape up any floor joints under floor to prevent glue escaping.
4. Inject the 2 part epoxy resin into holes until resin comes out of surrounding holes.
5. Insert wooden dowels into holes to add additional strength, similar to steel rods in concrete.
6. Wipe up any excess resin.
7. Allow 24-48hrs for resin to harden.
8. Assess treated area and if area still moving repeat steps 3-7.
9. Once area is solid, sand back heads of dowels and any excess dry resin.
10. Relay and fix carpet.